Alkylation reaction using delaminated zeolite supports as catalysts

ABSTRACT

Provided is an improved alkylation process using a delaminated SSZ-70 catalyst. The process comprises contacting a hydrocarbon feedstock comprising olefins and isoparaffins with a catalyst comprising delaminated SSZ-70 under alkylating reaction conditions. The delaminated SSZ-70 offers a zeolite layer with a single unit cell of thickness in one dimension, allowing an elimination of mass transfer in comparison with regular SSZ-70. This prevents coke formation inside zeolite channels and improves catalyst stability.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional No. 62/074,974, filed Nov. 4, 2014, entitled “Alkylation Reaction Using Delaminated Zeolite Supports as Catalysts”, the contents of which are herein incorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to delaminated zeolites and their use as catalysts in the hydroprocessing of hydrocarbons. More specifically, the present invention relates to the use of delaminated SSZ-70 as a catalyst in the alkylation of hydrocarbons.

BACKGROUND

Zeolites are widely used as acidic catalysts for refining applications attributed to their unique and uniform pore structure with sizes in the sub-nanometer range. The pore sizes of zeolites dictate the reaction in refining processes including hydroisomerization, hydrocracking, olefin alkylation and olefin oligomerization, and thus dictate reaction selectivity. However, hydroprocessing products often experience varying degrees of continuously (over)cracking when they diffuse out of micrometer-scale zeolitic channels. Thus elimination of these types of side-reactions is significant for efficiency improvement. One of the solutions for preventing overcracking is reduction of acidic strength. But this approach reduces the catalyst activity at the same time.

A. Corma et al. in “Delaminated zeolite precursors as selective acidic catalysts”, Nature, vol. 396, November 1998, pp 353-356, discusses delaminating MCM-22(P), the precursor of both MCM-22 and ERB-1 zeolites. The delaminated zeolite is designated ITQ-2, and was shown to have catalytic potential.

Molecular sieve SSZ-70 is known and is discussed in “Physiochemical Properties and Catalytic Behavior of the Molecular Sieve SSZ-70”, Archer et al. Chemistry of Materials, 2010, vol. 22, pp 2563-2572. A method for the synthesis of the SSZ-70 is discussed. Pure silica, borosilicate and aluminosilicate SSZ-70 materials were prepared and characterized. The catalytic activity of Al-SSZ-70 materials were tested using the CI (Constraint Index) test. U.S. Pat. Nos. 7,108,843 and 7,550,073 also discuss the synthesis of the molecular sieve SSZ-70, and its use in hydrocarbon conversion processes such as hydrocracking The disclosure of both U.S. Pat. Nos. 7,108,843 and 7,550,073 are expressly incorporated herein by reference in their entirety.

Providing a process for olefin alkylation to achieve a high quality alkylate would be quite useful for gasoline blending, as long as the catalyst exhibits good selectivity and stability.

SUMMARY

Provided is a process of alkylating hydrocarbons in the presence of a catalyst comprising delaminated SSZ-70. The delaminated SSZ-70 has been found to provide unexpected improvements in the catalysis of hydroprocessing hydrocarbons. It has been found that delaminated SSZ-70 offers a zeolite layer with a single unit cell of thickness in one dimension, allowing an elimination of mass transfer in comparison with regular SSZ-70 (non-delaminated). This prevents coke formation inside zeolitic channels and improves catalyst stability. The delaminated SSZ-70 zeolite also exhibits features of maintaining zeolite strength and spatial constraint of internal zeolitic framework. This provides opportunities to control novel chemistry by tailoring location of acidic sites for chemical reactions.

Among other factors, an improved alkylation process has been discovered which comprises contacting a hydrocarbon feedstock comprising olefins and isoparaffins with a catalyst comprising delaminated SSZ-70 under alkylating reaction condition. Superior selectivity and catalyst stability is achieved for the reaction of olefins and isoparaffins. The resulting product is a high quality alkylate useful for gasoline or gasoline blending.

BRIEF DESCRIPTION OF THE DRAWING

The Figure depicts acid sites on delaminated SSZ-70. It shows the possibility of preparing SSZ-70-based catalysts with a varying location of acidic sites, for example, (i) zeolitic acidic sites on both external and internal surface, (ii) zeolitic acidic sites on internal surface only, (iii) zeolitic acidic sites on external surface only.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to an improved alkylation process which allows one to achieve superior selectivity and catalyst stability. The process comprises contacting a hydrocarbon feed comprised of isoparaffins and olefins under alkylation conditions with a catalyst comprising delaminated SSZ-70. It has been found that delaminated SSZ-70 offers a zeolite layer with a single unit cell of thickness in one dimension, allowing an elimination of mass transfer in comparison with regular SSZ-70. The result is superior selectivity.

The delaminated SSZ-70 also exhibits features of maintaining zeolitic acidic strength and spatial constraint of the internal zeolite framework. This provides one with the opportunity of controlling novel chemistry by tailoring the location of acidic sites. Turning to the Figure, three scenarios are schematically provided of controlled location of acidic sites that can be prepared with starting materials of delaminated SSZ-70 in either the Al- or B-form.

The molecular sieve SSZ-70 is known, as is synthesis thereof. U.S. Pat. No. 7,108,843, issued Sep. 19, 2006, for example describes the molecular sieve SSZ-70 and a synthesis for preparing the molecular sieve. The SSZ-70 is characterized in U.S. Pat. No. 7,108,843 by its X-ray diffraction pattern before calcination and by its X-ray diffraction pattern after calcination. The disclosure of U.S. Pat. No. 7,108,843 is hereby expressly incorporated by reference herein in its entirety.

The delaminated SSZ-70 can be obtained by delaminating the SSZ-70 molecular sieve using conventional techniques of delamination. In one embodiment, the techniques described in U.S. 2012/0148487, published Jun. 14, 2012, would be quite effective, which publication is expressly incorporated herein by reference in their entirety.

In general, an aqueous mixture of chloride and fluoride anions, e.g., alkylammoniumhalides and the SSZ-70 is prepared. The aqueous mixture is maintained at a pH less than 12, e.g., about 9, and maintained at a temperature in the range of 5-150° C. for a length of time sufficient to effect the desired delamination. The oxide product is then recovered, e.g., by acidification to a pH of about 2 followed by centrifugation.

In one embodiment, a non-aqueous mixture of chloride and fluoride anions, i.e., a mixture comprising an organic solvent, is maintained at a temperature in the range of from 5-150° C. to effect desired delamination. The organic solvent can be any suitable organic solvent which swells the starting material such as dimethyl formamide (DMF). The delaminated product can then be recovered from the mixture. Generally, acidification is used to recover the product. Sonication prior to recovery need not be employed, but sonification can be employed in the process if desired.

The chloride and fluoride anions can be obtained from any source of the anions. Any compound which will provide the anions in aqueous solution can be used. The cation is generally not important. Providing the fluoride and chloride anions is important. Bromide anions can also be present, but both fluoride and chloride anions must be present. The cations can be any cation, with the use of alkylammonium cations being suitable in one embodiment. The alkyl group of such a cation can be any length, and in one embodiment ranges from 1-20 carbons. Tetrabutylammonium cations in particular have been found useful. The molar ratio of chloride to fluoride anions can be 100 or less, generally from 100:1 to 1:100. In one embodiment, the ratio can range from 50:1 to 1:50. It is the combination of the fluoride and chloride anions which has been discovered to be important.

The pH used in the synthesis when an aqueous mixture is used is lower than that generally used in delamination synthesis. The pH is generally 12 or less, but can be any pH which does not transform the silica in the zeolite to create an amorphous silica phase. A pH of 12 or less generally accomplishes this task and thereby allows one to obtain a delaminated layered zeolite precursor material substantially without an amorphous phase. In another embodiment, the pH is 11 or less, and even 10 or less, with a pH of about 9 or less also being quite advantageous. A pH of approximately 9 is typically used in fluoride-mediated synthesis of zeolites.

The temperature used in the process for either the aqueous or non-aqueous mixture can range widely. In general a temperature for the aqueous solution of from 5-150° C. is suitable. In another embodiment, the temperature can range from 50-100° C.

The length of time the zeolite is allowed to swell, and delaminate, in the aqueous solution can vary greatly. Generally, the time can vary from 30 minutes to one month. In one embodiment, the time ranges from 2 hours to 50 hours. In another embodiment, the time can range from 5 to 20 hours prior to collection of the product.

The delaminated oxide product is collected using conventional techniques such as centrifugation. An acid treatment step can be employed prior to centrifugation, and may be conveniently conducted by contacting the swollen or partially delaminated layered zeolite precursor material with a strong acid, e.g., a mineral acid such as hydrochloric acid or nitric acid, at low pH, e.g., pH 2. Collection of the resulting oxide material product can be performed by centrifugation.

The delaminated SSZ-70 is useful in a process for the alkylation of olefins with isoparaffins for making alkylate. The process comprises contacting C₂ to C₁₆ olefins and C₄-C₁₀ isoparaffins under olefin alkylation conditions in the presence of a catalyst comprising the delaminated SSZ-70. The catalyst can comprise pure delaminated SSZ-70 or in mixture with any suitable conventional catalyst, and can be present in the catalyst in amounts as small as 2 parts by weight. Generally, the catalyst will comprise at least 2 parts by weight of the delaminated SSZ-70.

The delaminated SSZ-70 can also be used for removing benzene from gasoline by alkylating the benzene with olefins.

For high catalytic activity, the delaminated SSZ-70 zeolite can be in any form, but is preferred predominantly in its hydrogen ion form. It is preferred that, after calcination, at least 80% of the cation sites are occupied by hydrogen ions and/or rare earth ions.

Examples of suitable alkylation feedstocks which may be alkylated by the present process of the invention include various streams in a petroleum refinery, a gas-to-liquid conversion plant, a coal-to-liquid conversion plant, or in naphtha crackers, middle distillate cracker or wax crackers, FCC off-gas, FCC light naphtha, coker off-gas, coker naphtha, hydrocracker naphtha, and the like. Such streams generally contain isoparaffin(s) and/or olefin(s). Such streams can be fed to the reactor of a hydrocarbon conversion system of the present invention via one or more feed dryer units.

Examples of separate olefin containing streams include FCC off-gas, coker gas, olefin metathesis unit off-gas, polyolefin gasoline unit off-gas, methanol to olefin unit off-gas, FCC light naphtha, coker light naphtha, Fischer-Tropsch unit condensate, and cracked naphtha. Some olefin containing streams may contain two or more olefins selected from ethylene, propylene, butylenes, pentenes, and up to C₁₆ olefins.

The olefin containing stream can be a fairly pure olefinic hydrocarbon cut or can be a mixture of hydrocarbons having different chain lengths thus a wide boiling range. The olefinic hydrocarbon can be terminal olefin (an alpha olefin) or can be an internal olefin (having an internal double bond). The olefinic hydrocarbon chain can be either straight chain or branched or a mixture of both. In one embodiment of the present invention, the olefinic feed may comprise a mixture of mostly linear olefins from C₂ to about C₁₆. The olefins may be mostly, but not entirely, alpha olefins. In another embodiment of the present invention, the olefinic feed can comprise 50% of a single alpha olefin species. In another embodiment of the present invention, the olefinic feed can comprise at least 20% of alpha olefin species.

In one embodiment, olefins in the feed may also undergo oligomerization when contacted with delaminated SSZ-70 catalyst in the hydrocarbon conversion zone. Delaminated SSZ-70 catalyzed olefin oligomerization may take place under the same or similar conditions as the olefin-isoparaffin alkylation process. As a result, in an embodiment of the present invention, both olefin oligomerization and olefin-isoparaffin alkylation may take place in a single reaction zone of the hydrocarbon conversion process. In one embodiment of the present invention, an oligomeric olefin produced may be subsequently alkylated by an isoparaffin to provide a distillate, and/or lubricant component or base oil product.

Examples of isoparaffin containing streams include, but are not limited to, FCC naphtha, hydrocracker naphtha, coker naphtha, Fisher-Tropsch unit condensate, and cracked naphtha. Such streams can comprise a mixture of two or more isoparaffins. In a one embodiment, the feed for a delaminated SSZ-70 catalyzed process can comprise isobutane, which may be obtained, for example, from a hydrocracking unit, or may be purchased.

Suitable olefins for the alkylation of an aromatic hydrocarbon are those containing 2 to 16, preferably 2 to 4, carbon atoms, such as ethylene, propylene, butene-1, trans-butene-2 and cis-butene-2, or mixtures thereof. There may be instances where pentenes are desirable. The preferred olefins are butenes. Longer chain alpha olefins may be used as well.

When alkylation of isoparaffins and olefins is the process conducted, reaction conditions can be as follows. It is preferred that the molar ratio of isoparaffins to olefins be greater than four-to-one to prevent rapid catalyst fouling. The reaction temperature may range from 100° F. to 600° F., preferably 250° F. to 450° F. The reaction pressure should be sufficient to maintain at least a partial liquid phase in order to retard catalyst fouling. This is typically 50 psig to 1000 psig depending on the feedstock and reaction temperature. Contact time may range from 10 seconds to 10 hours, but is usually from 5 minutes to an hour. The weight hourly space velocity (WHSV), in terms of grams (pounds) of isoparaffins and olefins per gram (pound) of catalyst per hour, is generally within the range of about 0.5 to 50.

In one embodiment, the delaminated SSZ-70 catalyst comprises a noble metal selected from the group consisting of nickel (Ni), palladium (Pd), platinum (Pt), ruthenium (Ru), rhodium (Rh), iron (Fe), gold (Au), silver (Ag) and mixtures thereof. In another embodiment, the delaminated SSZ-70 catalyst contains at least one metal selected from Groups 6 through 8 of the Periodic Table.

The deactivated catalyst can be regenerated by hydrogenation or hydrocracking of coke or heavy hydrocarbons deposited on its surface under hydrogenation and hydrocracking reaction conditions.

The following examples are provided to further illustrate the present invention, and are not meant to be limiting.

EXAMPLE

Preparation of Al-SSZ-70

7.67 g aluminum hydroxide (Reheis F-2000) was added to 395.55 g NaOH (1M) in a 1 gallon liner. 240 g Cabosil fumed silica was slowly added while stirring. At the same time, 1707.47 g 1,3-diisobutylimidazolium hydroxide (9 wt %, SDAOH-1) and 149.27 g deionized water was added to the liner. The final molar composition was 1SiO₂:0.01Al₂O₃:0.2 SDAOH-1:0.1NaOH:30H₂O. The liner was placed into a 1 gallon, overhead stirred autoclave. The temperature was increased to 160° C. with a ramp time of 8 h and a stir rate of 150 rpm. The reaction mixture was synthesized for 120 h. The final solids were filtered and washed with deionized water to a conductivity of <50 μS/cm.

Preparation of B-SSZ-70

2.91 g H₃BO₃ was added to 84.20 g NaOH (1M) in a 1 L Teflon liner. 50.52 g of Cabosil fumed silica was slowly added while stirring. At the same time, 413.6 g 1,3-Bis(cyclohexyl)imidazolium hydroxide (0.40 M, SDAOH-2) was added to the liner. The final molar composition was 1SiO₂:0.03B₂O₃:0.2SDAOH-2:0.1NaOH:30H₂O. The liner was placed into a 1 L, overhead stirred, Parr autoclave. The temperature was increased to 160° C. with a ramp time of 8 h and a stir rate of 70 rpm. The reaction mixture was synthesized for 116 h. The final solids were filtered and washed with deionized water to a conductivity of 26 μS/cm.

Preparation of Delaminated B-SSZ-70

5 g of as-made B-SSZ-70 was added to a 500 mL, 1-neck, round-bottom flask. 200 mL N,N-dimethylformamide, 5.5 g cetyltrimethylammonium bromide, 8.5 g tetrabutylammonium fluoride trihydrate, and 8.5 g tetrabutylammonium chloride were added to the flask. The contents of the flask were stirred in a 95° C. oil bath for 48 h. The contents of the flask were then poured into a 500 mL wide-mouth bottle and sonicated in an ice bath for 2 h using a sonicator made by Sonics and Materials Inc. (Vibracell VC 750, 35% power) operating under pulse mode (4 s on and 1 s off). The delaminated solution was divided into four equal parts and poured into four 250 mL centrifuge bottles. 200 mL tetrahydrofuran was added to each centrifuge bottle, and the bottles were centrifuged at 8500 rpm (11000 g) for 10 min. The solution was decanted, 250 mL fresh THF was added to each bottle, and the solids were redispersed into the solution. The bottles were centrifuged and decanted. 250 mL diethyl ether was added to each bottle and the solids were redispersed into the solution. The bottles were centrifuged, decanted, and the solids were dried at 80° C. The sample was calcined at 550° C. for six hours at a ramp rate of 1° C./min in flowing air.

Preparation of Al-Exchanged Delaminated Al-SSZ-70

3 g of delaminated B-SSZ-70 was added to a 250 mL, 1-neck, round-bottom flask. 75 g deionized water and 11.25 g aluminum nitrate nonahydrate were added to the flask. The contents of the flask were stirred in a 95° C. oil bath for 96 h. The mixture was filtered and washed with 300 mL HCl (pH=2). The mixture was filtered and washed with another 300 mL HCl. The mixture was filtered and washed with deionized water to a pH of 7. The solids were dried at 80° C.

Preparation of a Catalyst Base Containing 10% Al-SSZ-70 (Catalyst Base-A, Base Case)

A comparative catalyst was prepared per the following procedure: 90 parts by weight pseudo boehmite alumina powder (obtained from Sasol), and 10 parts by weight of Al-SSZ-70 zeolite were mixed well. The SSZ-70 zeolite employed had the following properties: a SiO₂/Al₂O₃ mole ratio of about 80. A diluted HNO₃ acid aqueous solution (1 wt. %) was added to the mix powder to form an extrudable paste. The paste was extruded in 1/16 inch asymmetric quadrilobe shape, and dried at 250° F. (121° C.) overnight. The dried extrudates were calcined at 850° F. (454° C.) for 1 hour with purging excess dry air and cooled down to room temperature.

Preparation of 0.5wt % Pt Catalyst Containing 10% Al-SSZ-70 (Catalyst-A, Base Case)

Impregnation of Pt metal was done using an aqueous solution containing 3.3% Pt salt in concentrations equal to the target metal loadings of 0.5 wt. % Pt based on the bulk dry weight of the finished catalyst. The total volume of the solution matched the 103% water pore volume of the above calcined base extrudate sample (incipient wetness method). The metal solution was added to the base extrudates of base-A (base case) gradually while tumbling the extrudates. When the solution addition was completed, the soaked extrudates were aged for 2 hours. Then the extrudates were dried at 250° F. (121° C.) overnight. The dried extrudates were calcined at 662° F. (350° C.) for 1 hour with purging excess dry air, and cooled down to room temperature. The performance of this catalyst was evaluated with nC16 pure compound.

Preparation of a New Catalyst Base Containing 10% Delaminated Al-SSZ-70 (Catalyst Base-B)

A new isomerization-improved catalyst base was prepared per the following procedure: 90 parts by weight pseudo boehmite alumina powder (obtained from Sasol), and 10 parts by weight of delaminated Al-SSZ-70 zeolite were mixed well. A diluted HNO₃ acid aqueous solution (1 wt. %) was added to the mix powder to form an extrudable paste. The paste was extruded in 1/16 inch asymmetric quadrilobe shape, and dried at 250° F. (121° C.) overnight. The dried extrudates were calcined at 850° F. (454° C.) for 1 hour with purging excess dry air and cooled down to room temperature.

Preparation of 0.5 wt % Pt Catalyst Containing 10% Delaminated Al-SSZ-70 (Catalyst-B)

Impregnation of Pt was done using an aqueous solution containing 3.3 wt. % Pt salt in concentrations equal to the target metal loadings of 0.5 wt. % Pt based on the bulk dry weight of the finished catalyst. The total volume of the solution matched the 103% water pore volume of the above calcined base extrudate sample (incipient wetness method). The metal solution was added to the base extrudates of base-B gradually while tumbling the extrudates. When the solution addition was completed, the soaked extrudates were aged for 2 hours. Then the extrudates were dried at 250° F. (121° C.) overnight. The dried extrudates were calcined at 662° F. (350° C.) for 1 hour with purging excess dry air, and cooled down to room temperature. The performance of this catalyst was evaluated with nC₁₆ pure compound.

Preparation of a Catalyst New Base Containing 2% Delaminated Al-SSZ-70 (Catalyst Base-C)

A new isomerization-improved catalyst base was prepared per the following procedure: 25 parts by weight pseudo boehmite alumina powder (obtained from Sasol), 73 parts by weight of silica-alumina powder (obtained from Sasol), and 2 parts by weight of delaminated Al-SSZ-70 zeolite were mixed well. A diluted HNO₃ acid aqueous solution (1 wt. %) was added to the mix powder to form an extrudable paste. The paste was extruded in 1/16 inch asymmetric quadrilobe shape, and dried at 250° F. (121° C.) overnight. The dried extrudates were calcined at 850° F. (454° C.) for 1 hour with purging excess dry air and cooled down to room temperature.

Preparation of 0.5 wt % Pt Catalyst Containing 2% Delaminated Al-SSZ-70 (Catalyst-C)

Impregnation of Pt was done using an aqueous solution containing 3.3 wt. % Pt salt in concentrations equal to the target metal loadings of 0.5 wt. % Pt based on the bulk dry weight of the finished catalyst. The total volume of the solution matched the 103% water pore volume of the above calcined base extrudate sample (incipient wetness method). The metal solution was added to the base extrudates of base-C gradually while tumbling the extrudates. When the solution addition was completed, the soaked extrudates were aged for 2 hours. Then the extrudates were dried at 250° F. (121° C.) overnight. The dried extrudates were calcined at 662° F. (350° C.) for 1 hour with purging excess dry air, and cooled down to room temperature. The performance of this catalyst was evaluated with nC16 pure compound.

Preparation of a New Catalyst Base Containing 3% Delaminated B-SSZ-70 (Catalyst Base-D)

A new isomerization-improved catalyst base was prepared per the following procedure: 25 parts by weight pseudo boehmite alumina powder (obtained from Sasol), 72 parts by weight of silica-alumina powder (obtained from Sasol), and 3 parts by weight of delaminated B-SSZ-70 zeolite were mixed well. A diluted HNO₃ acid aqueous solution (1 wt. %) was added to the mix powder to form an extrudable paste. The paste was extruded in 1/16 inch asymmetric quadrilobe shape, and dried at 250° F. (121° C.) overnight. The dried extrudates were calcined at 850° F. (454° C.) for 1 hour with purging excess dry air and cooled down to room temperature.

Preparation of 0.5 wt % Pt Catalyst Containing 3% Delaminated B-SSZ-70 (Catalyst-D)

Impregnation of Pt was done using an aqueous solution containing 3.3 wt. % Pt salt in concentrations equal to the target metal loadings of 0.5 wt. % Pt based on the bulk dry weight of the finished catalyst. The total volume of the solution matched the 103% water pore volume of the above calcined base extrudate of base-D (incipient wetness method). The metal solution was added to the base extrudates gradually while tumbling the extrudates. When the solution addition was completed, the soaked extrudates were aged for 2 hours. Then the extrudates were dried at 250° F. (121° C.) overnight. The dried extrudates were calcined at 662° F. (350° C.) for 1 hour with purging excess dry air, and cooled down to room temperature. All the catalysts and their supports were characterized as follows:

Brönsted acidity: determined by isopropylamine-temperature-programmed desorption (IPam TPD) adapted from the published descriptions by T. J. Gricus Kofke, R. K. Gorte, W. E. Farneth, J. Catal. 114, 34-45, 1988; T. J. Gricus Kifke, R. J. Gorte, G. T. Kokotailo, J. Catal. 115, 265-272, 1989; J. G. Tittensor, R. J. Gorte and D. M. Chapman, J. Catal. 138, 714-720, 1992. Samples are pre-treated at 400-500° C. for 1 hour in flowing dry H₂. The dehydrated samples are then cooled down to 120° C. in flowing dry He and held at 120° C. for 30 minutes in a flowing He saturated with isopropylamine for adsorption. The isopropylamine-saturated samples are then heated up to 500° C. at a rate of 10° C./min in flowing dry He. The Brönsted acidity is calculated based on the weight loss vs. temperature by TGA and effluent NH₃ and propene by Mass Spectrometer.

Surface area: determined by N₂ adsorption at its boiling temperature. BET surface area is calculated by the 5-point method at P/P₀=0.050, 0.088, 0.125, 0.163, and 0.200. Samples are first pre-treated at 400° C. for 6 hours in the presence of flowing, dry N₂ so as to eliminate any adsorbed volatiles like water or organics.

TABLE 1 Properties of calcined catalyst bases containing Al-SSZ-70 and delaminated Al-SSZ-70 Ext. Brönsted Micropore SA, acidity, Catalyst base Zeolite volume, cc/g m2/g μmol/g Base-A Original SSZ-70 (w/o 0.0214 207 161 (base case) delaminated) Base-B Delaminated SSZ-70 0.0068 277 131

The high external surface area of the support of the new catalyst base-B in comparison with the base case catalyst support of catalyst base-A is contributed to the high external surface area of delaminated Al-SSZ-70. In contrast to the base case catalyst base-A, the delaminated SSZ-70-containing catalyst base-B showed a lower micropore volume. Delaminated SSZ-70 showed less Brönsted acidic density than its original precursor.

TABLE 2 Properties of calcined catalyst bases containing delaminated Al-SSZ-70 and delaminated B-SSZ-70 Surface Pore Mesopore Brönsted Area, volume, size, acidity, Catalyst base Zeolite m2/g cm3/g nm μmol/g Base-C 2% 421 0.81 11.3 142 Delaminated Al-SSZ-70 Base-D 3% 420 0.80 11.2 158 Delaminated B-SSZ-70

The high Brönsted acidity of the catalyst base-D suggests Al exchanged to the B site of zeolite framework during the extrusion process. Thus, it is concluded that the Al exchange process can be eliminated in the preparation of hydroprocessing catalysts using delaminated B-SSZ-70 zeolite.

It is expected that if the delaminated SSZ-70, whether in the delaminated Al-SSZ-70 or B-SSZ-70 form, was used in an alkylation reaction between isoparaffins and olefins, exceptional stability and selectivity would be observed.

The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. 

What is claimed is:
 1. An alkylation process comprising contacting a hydrocarbon feedstock comprising at least one C₂ to C₁₆ olefin and at least one C₄ to C₁₀ isoparaffin with a catalyst comprising delaminated SSZ-70 under alkylation conditions whereby the at least one C₂ to C₁₆ olefin is alkylated by the at least one C₄ to C₁₀ isoparaffin.
 2. The process of claim 1, wherein a portion of the at least one C₂ to C₁₆ olefin is oligomerized, and then the oligomerized olefin is alkylated by the at least one C₄ to C₁₀ isoparaffin.
 3. The process of claim 1, wherein the alkylating reaction produces an alkylate for gasoline or gasoline blending.
 4. The process of claim 1, wherein the catalyst further comprises at least one noble metal.
 5. The process of claim 1, wherein the delaminated SSZ-70 is a delaminated Al-SSZ-70 material.
 6. The process of claim 1, wherein the delaminated SSZ-70 is a delaminated B-SSZ-70 material.
 7. The process of claim 1, wherein the delaminated SSZ-70 is regenerated under hydrogenation or hydrocracking reaction conditions.
 8. The process of claim 1, wherein the C₂ to C₁₆ olefins comprise greater than 50% linear olefins.
 9. The process of claim 1, wherein a molar ratio of isoparaffins to olefins is greater than four. 